Principal Additive Manufacturing Engineer

About Arcturus

Arcturus is creating a wire technology stack using carbon nanomaterials to overcome materials limitations where performance breaks down at real operating temperatures. The technology is designed to significantly improve electric motors for drones and robotics, heat sinks, and the energy grid.

The Role

This is a ground-floor opportunity to join as an early principal technical hire and help define how Arcturus turns metal additive manufacturing into a core company capability. You will own major AM process development workstreams and serve as a senior technical voice on metal AM process physics. This high-ownership individual contributor role reports directly to the CEO.

Key Responsibilities

• Own major additive manufacturing workstreams across LPBF, DED, and related metal processing approaches for infused metal parts and wire
• Develop process windows for aluminum and copper systems that preserve conductivity, mechanical integrity, and carbon nanomaterial performance through fabrication
• Lead parameter development, build strategy, scan strategy, thermal management, and machine/process troubleshooting
• Serve as senior technical authority on melt pool behavior, lasers, machine behavior, powder/feedstock handling, and print quality
• Lead design-for-additive-manufacturing decisions including build orientation, support strategy, geometry tradeoffs, and distortion risk assessment
• Diagnose and resolve print failures including porosity, cracking, distortion, poor bonding, inconsistent density, geometry drift, and surface quality issues
• Build process maps connecting machine inputs, feedstock, atmosphere, thermal history, and post-processing to material outcomes
• Partner with nanomaterials, process, characterization, mechanical, and product engineering teams to connect print process to final conductor performance
• Mentor team members and help solve hard manufacturing problems

Ideal Candidate

You bring: Deep expertise in metal additive manufacturing (LPBF and/or DED), process development, materials characterization, and troubleshooting. You excel at translating ambiguous technical goals into repeatable process windows and measurable performance. You thrive in early-stage, high-ownership roles solving novel manufacturing challenges.

Salary Disclosure: This listing shows an editorial market estimate of $80,000–$130,000 USD annually. This is not employer-provided compensation and may vary significantly based on experience, location, and qualifications. Please confirm actual salary range with Arcturus during the application process.